Input Shaft: Inspection

INSPECT INPUT SHAFT
1. Using a dial indicator, check the input shaft runout.
  Maximum runout: 0.015 mm (0.000591 in.)
  
  If the runout exceeds the maximum, replace the input shaft.
  
  Fig 1: Checking Input Shaft Runout
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
2. Using a micrometer, measure the outer diameter of the input shaft journal surface at the locations indicated.
  Standard outer diameter:
  
  Part A:
  
  24.885 to 24.900 mm (0.9797 to 0.9803 in.)
  
  Part B:
  
  28.991 to 29.006 mm (1.1414 to 1.1420 in.)
  
  Part C:
  
  30.985 to 31.000 mm (1.2198 to 1.2204 in.)
  
  Part D:
  
  24.985 to 25.000 mm (0.9836 to 0.9842 in.)
  
  Minimum outer diameter:
  
  Part A:
  
  24.885 mm (0.9797 in.)
  
  Part B:
  
  28.991 mm (1.1414 in.)
  
  Part C:
  
  30.985 mm (1.2198 in.)
  
  Part D:
  
  24.985 mm (0.9836 in.)
  
  If any of the outer diameters are less than the minimum, replace the input shaft.
  
  Fig 2: Measuring Outer Diameter Of Input Shaft Journal Surface At Locations Indicated
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 4TH GEAR
1. Using a cylinder gauge, measure the inside diameter of the 4th gear.
  Standard inside diameter:
  
  34.015 to 34.031 mm (1.3391 to 1.3398 in.)
  
  Maximum inside diameter:
  
  34.031 mm (1.3398 in.)
  
  If the inside diameter exceeds the maximum, replace the 4th gear.
  
  Fig 3: Measuring Inside Diameter Of 4Th Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 3RD GEAR
1. Using a cylinder gauge, measure the inside diameter of the 3rd gear.
  Standard inside diameter:
  
  36.015 to 36.031 mm (1.4179 to 1.4185 in.)
  
  Maximum inside diameter:
  
  36.031 mm (1.4185 in.)
  
  If the inside diameter exceeds the maximum, replace the 3rd gear.
  
  Fig 4: Measuring Inside Diameter Of 3Rd Gear
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 4TH GEAR SYNCHRONIZER RING
1. Check for wear and damage.
2. Coat the 4th gear cone with gear oil.
3. Turn the synchronizer ring in one direction while pushing it against the 4th gear cone.
4. Check that the ring locks.
  If the synchronizer ring does not lock, replace the synchronizer ring.
  
  Fig 5: Checking Ring Locks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a feeler gauge, measure the clearance between the synchronizer ring and the gear spline end.
  Standard clearance:
  
  0.75 to 1.65 mm (0.0295 to 0.0649 in.)
  
  Minimum clearance:
  
  0.75 mm (0.0295 in.)
  
  If the clearance is less than the minimum, replace the synchronizer ring.
  
  Fig 6: Measuring Clearance Between Synchronizer Ring And Gear Spline End
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT 3RD GEAR SYNCHRONIZER RING
1. Check for wear and damage.
2. Coat the 3rd gear cone with gear oil.
3. Turn the synchronizer ring in one direction while pushing it against the 3rd gear cone.
4. Check that the ring locks.
  If the synchronizer ring does not lock, replace the synchronizer ring.
  
  Fig 7: Checking Ring Locks
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
5. Using a feeler gauge, measure the clearance between the synchronizer ring and the gear spline end.
  Standard clearance:
  
  0.65 to 1.75 mm (0.0256 to 0.0689 in.)
  
  Minimum clearance:
  
  0.65 mm (0.0256 in.)
  
  If the clearance is less than the minimum, replace the synchronizer ring.
  
  Fig 8: Measuring Clearance Between Synchronizer Ring And Gear Spline End
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
INSPECT NO. 2 TRANSMISSION HUB SLEEVE
1. Check the sliding condition between the No. 2 transmission hub sleeve and the No. 2 transmission clutch hub.
2. Check that the edges of the No. 2 transmission hub sleeve spline gear are not worn down.
  
  Fig 9: Checking Sliding Condition Between No. 2 Transmission Hub Sleeve And No. 2 Transmission Clutch Hub
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002
3. Using a vernier caliper, measure the width of the No. 2 transmission hub sleeve groove (B) and the thickness of the claw part on the No. 2 gear shift fork (A), and calculate the clearance.
  Standard clearance (B - A):
  
  0.15 to 0.35 mm (0.00591 to 0.0137 in.)
  
  If the clearance is out of specification, replace the No. 2 transmission hub sleeve and No. 2 gear shift fork.
  
  Fig 10: Measuring Width Of No. 2 Transmission Hub Sleeve Groove (B) And Thickness Of Claw Part On No. 2 Gear Shift Fork (A)
  Courtesy of © TOYOTA, LICENSE AGREEMENT TMS1002